Automated self-aligning mechanical fastener

ABSTRACT

Corresponding threaded mechanical fasteners are automatically aligned with an alignment guide. The alignment guide includes a tapered cavity defined in a housing. As the threaded mechanical fasteners are moved towards one another to mate, the tapered cavity in the alignment guide causes the threaded mechanical fasteners to align with each other. The mechanical fasteners can connect a modular rechargeable battery to a battery receptacle in a vehicle.

RELATED APPLICATIONS

This application is a divisional of and claims priority to U.S.application Ser. No. 15/185,973, now U.S. Pat. No. 10,359,066, entitled“Automated Self-Aligning Mechanical Fastener”, filed Jun. 17, 2016,which claims priority to U.S. Provisional Application Ser. No.62/180,680 entitled “Self-Aligning Mechanical Fastener,” filed on Jun.17, 2015, all of which are hereby incorporated by reference.

TECHNICAL FIELD

The present disclosure generally relates to mechanical fasteners formating physical components of an apparatus.

BACKGROUND

Physical components often need to be mated or joined together to form anapparatus. Such components can be mated or joined together with anadhesive (e.g., glue), a clamp, a nail, a screw, a bolt, or a similardevice. Screws and bolts include a head and a threaded shaft that isdriven into one or more physical components to mechanically secure thecomponents together. A driving apparatus (screwdriver, wrench, Allenwrench, or similar device) drives the head, which causes the threadedshaft to rotate. A bolt or nut can be attached to a proximal end of thethreaded shaft, which can be rotatably tightened to generate amechanical force between the head and the bolt/nut to secure one or moreparts therebetween.

In order to drive the head, accurate mechanical alignment is requiredbetween the driving apparatus and the head. For example, a screw head orbolt head includes a recessed portion to receive a corresponding end ofa flathead or Phillips screwdriver. Bolt heads can also have a raised orrecessed hexagonal shape that allows the bolts to be engaged by awrench. In addition, accurate mechanical alignment is required betweenthe threaded shaft and a bolt or nut to drive the threaded shaft intothe bolt/nut.

Although such mechanical alignment can be done manually by a human withrelative ease, challenges arise in automated systems. For example,robotic systems need expensive and complex optical devices for guidanceand alignment. In addition, robotic systems need to manipulate and keeptrack of multiple loose/detached components (e.g., screws, bolts, etc.).

The present disclosure provides improved and lower-cost alignmentsystems for mechanical fasteners.

SUMMARY

The following description and drawings set forth certain illustrativeimplementations of the disclosure in detail, which are indicative ofseveral exemplary ways in which the various principles of the disclosuremay be carried out. The illustrative examples, however, are notexhaustive of the many possible embodiments of the disclosure. Otherobjects, advantages and novel features of the disclosure will be setforth in the following detailed description of the disclosure whenconsidered in conjunction with the drawings.

In an aspect, the invention is directed to a self-aligning mechanicalfastener system. The system includes a first apparatus comprising afirst threaded fastener disposed at least partially in a first fastenerguide hole defined in a first fastener guide housing; and a motor inmechanical communication with said first fastener component. The systemalso includes a second apparatus comprising a second threaded fastenerdisposed at least partially in a second fastener hole defined in asecond fastener housing, the second fastener configured to mate with thefirst threaded fastener; a second fastener alignment guide disposed onthe second fastener housing, the second fastener alignment guideincluding a hollow body having a hollow body aperture defined by aninternal tapered wall, the hollow body aperture having a first width ata first end of the hollow body and a second width at a second end of thehollow body, the first width greater than the second width, the secondwidth configured to align the first threaded fastener with the secondthreaded fastener when the first fastener guide housing is disposed inthe hollow body aperture of the hollow body aperture of the secondfastener alignment guide; and a plate connecting the second end of thesecond fastener alignment guide to the second fastener guide housing,the plate having a plate hole in alignment with the hollow body apertureand the second fastener hole, the plate hole having a plate hole widthless than a width of at least a portion of the second threaded fastenerdisposed in the second fastener hole, wherein the plate secures at leasta portion of the second threaded fastener in the second fastener hole.

In another aspect, the invention is directed to an apparatus comprising:a housing including a housing hole defined in a housing face of thehousing; a threaded fastener including at least a portion of thefastener disposed in the hole, the at least a portion of the fastenerhaving a fastener width; a plate disposed on the housing face, the platehaving a plate hole aligned with the housing hole, the plate hole havinga width less than the fastener width, wherein the plate retains the atleast a portion of the fastener in the housing hole; and an alignmentguide including a body having opposing first and second faces, the firstface disposed on the plate, the body having a cavity extending from thefirst face to the second face, the cavity having a first width at thefirst face and a second width at the second face, the second widthgreater than the first width, the cavity aligned with the plate hole andthe housing hole.

In another aspect, the invention is directed to a method comprising:with a robot, raising a portable apparatus towards a stationaryapparatus, the portable apparatus including an alignment guide includinga body having opposing first and second faces, the body having a cavityextending from the first face to the second face, the cavity having afirst width at the first face and a second width at the second face, thesecond width greater than the first width; inserting the stationaryapparatus into the cavity on the second face of the portable apparatus;aligning a first threaded fastener at least partially disposed in afirst housing of the stationary apparatus with a corresponding secondthreaded fastener at least partially disposed in a second housing of theportable apparatus, the second housing disposed on the second face ofthe alignment guide, the first threaded fastener aligned with the cavityin the alignment guide; and rotating the first threaded fastener toengage and secure the first threaded fastener with the correspondingsecond threaded fastener.

This overview is intended to provide an overview of subject matter ofthe present patent application. It is not intended to provide anexclusive or exhaustive explanation of the invention. Furtherlimitations and disadvantages of conventional and traditional approacheswill become apparent to one of skill in the art, through comparison ofsuch systems with some aspects of the present invention as set forth inthe remainder of the present application with reference to the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and advantages of the presentinvention, reference is made to the following detailed description ofpreferred embodiments and in connection with the accompanying drawings,in which:

FIG. 1 illustrates a cross section of an exemplary automated system thatincludes a mechanical fastener;

FIG. 2 illustrates a perspective view of a cross section of theautomated system of FIG. 1;

FIG. 3 illustrates a side view of an exemplary automated system havingan alternative configuration;

FIG. 4 illustrates the automated system of FIG. 3 during a first stageof alignment;

FIG. 5 illustrates the automated system of FIG. 3 during a second stageof alignment;

FIG. 6 illustrates the automated system of FIG. 3 during a third stageof alignment;

FIG. 7 illustrates the automated system of FIG. 3 in a fully-alignedstate;

FIG. 8 illustrates an automated system having an alternativeconfiguration;

FIG. 9 illustrates the automated system of FIG. 8 during a first stageof alignment;

FIG. 10 illustrates the automated system of FIG. 8 during a second stageof alignment;

FIG. 11 illustrates the automated system of FIG. 8 during a third stageof alignment;

FIG. 12 illustrates the automated system of FIG. 8 in a fully-alignedstate;

FIG. 13 illustrates a perspective view of an automated system includinga robotic system and a removable apparatus in a disconnected state; and

FIG. 14 illustrates a perspective view of the automated system of FIG.13 where each removable apparatus is in a secured state.

DETAILED DESCRIPTION

FIG. 1 illustrates a cross section of an exemplary automated system 10that includes a mechanical fastener. The system includes a roboticsystem 20 for driving a bolt 30. The robotic system 20 includes anactuating mechanism 40 (e.g., a motor) having an actuator gear 45 thatmechanically communicates with a bolt gear 50. In some embodiments, achain connects actuator gear 45 and bolt gear 50. Alternatively,actuator gear 45 and bolt gear 50 interleave each other. The bolt gear50 is mechanically coupled to a head 32 of the bolt 30 to provide torquethereto. A shaft 35 of the bolt 30 is disposed in a channel 65 definedin bolt guide 60. The bolt guide 60 is attached to a support plate 70,which can be connected to a larger system (e.g., an electric vehicle). Athreaded portion 34 of the bolt shaft extends beyond the bolt guide 60to engage nut 120. A thrust bearing 80 can be disposed between the head32 of the bolt 30 and the support plate 70 to reduce frictiontherebetween. Additional sliding mechanical interfaces, includinglubricated or polished metal surfaces, ceramics, polymers, or bearingscan facilitate the smooth movement of contacting parts against eachother in any of the present embodiments as would suit a particularapplication. Therefore, the particular configurations of the shownillustrative examples are not intended to be limiting, and those skilledin the art will appreciate equivalent or alternate embodiments andarrangements consistent with the present disclosure, which are alsocomprehended by the present disclosure and claims.

The bolt 30 and nut 120 provide a mechanical connection between (a) boltguide 60 and support plate 70 (and anything connected to support plate70) and (b) removable apparatus 100. The removable apparatus 100includes a body 110 having a channel 115 defined therein to hold nut120, which is disposed on a spring 130. The channel 115 can be square,hexagonal, or a similar shape (e.g., an angular shape) in a second crosssection orthogonal to the plane defining the side view illustrated inFIG. 1. The shape and size of channel 115 are configured to prevent thenut 120 from rotating when it is engaged by the bolt 30.

A plate 140 is disposed on the body 110. The plate 140 can be connectedto a larger system, such as a tray that holds multiple modularreplaceable electric batteries as described below. The plate 140includes a hole 145 disposed over the channel 115. The hole 145 has asmaller diameter than the channel 115 to retain the nut 120 in thechannel 115. A hollow tapered guide 150 is disposed on the plate 140.The tapered guide 150 includes a tapered portion 152 and a channelportion 154. The tapered portion 152 tapers from a wide diameter to thenarrower diameter of the channel portion 154. The width of the channelportion 154 is configured to secure the bolt guide 60 so that thethreaded portion 34 of bolt 30 is aligned with the nut 120 through hole145 and channel 115. In some embodiments, the width of the channelportion 154 is about 0.25″ to about 0.5″ larger than the width of thebolt guide 60.

In operation, the removable apparatus 100 is moved (e.g., by a secondrobotic system) below the automated system 10 for connection thereto.The removable apparatus 100 is positioned so that the nut 120 is inapproximate alignment with the bolt 30 (e.g., as illustrated in FIG. 1).The removable apparatus 100 and the automated system 10 are broughtcloser to one another so that the bolt 30 and nut 120 are in contactwith one another. In some embodiments, the removable apparatus 100 ismoved towards (e.g., raised, positioned from the side, etc.) theautomated system 10 (i.e., towards bolt guide 60). In addition, or inthe alternative, the automated system 10 including bolt guide 60 can bemoved towards (e.g., lowered, positioned from the side, etc.) theremovable apparatus 100.

If the alignment of the nut 120 and the bolt 30 is offset, the boltguide 60 touches a sidewall of the tapered portion 152 of the taperedguide 150 as the removable apparatus is raised. The tapered portion 152causes the bolt guide 60 to align with and pass through the channelportion 154 resulting in alignment of the bolt 30 and nut 120.

When the bolt 30 contacts the nut 120, the spring 130 provides a forceto press the nut 120 against the bolt 30 to cause the nut 120 to engagewith the bolt 30 as the actuator 40 turns the bolt 30. The threadedportion 34 is driven into the bolt 30 by the actuator 40 until the boltguide 60 contacts the plate 140 and a minimum torque level is achieved,resulting in a secure mechanical connection between the removableapparatus 100 and the automated system 10. The actuator 40 can include asensor to measure the torque applied to the bolt 30. When the minimum orpredetermined torque level is reached, a feedback circuit can cause theactuator 40 to stop driving the bolt 30. The minimum/predeterminedtorque level can be adjusted manually (e.g., by user input from anoperator) or automatically (e.g., based on the type of removableapparatus 100, bolt 30, nut 120, etc.).

Although the automated system 10 has been described as stationary andthe removable apparatus 100 is described as moveable, it is recognizedthat the converse can also apply. In other words, the automated system10 can be moveable and the removable apparatus 100 can be stationary.Alternatively, both the removable apparatus 100 and the automated system10 can be moveable.

In some embodiments, the automated system 10 is disposed in an electricvehicle (e.g., in the bottom of the vehicle). The removable apparatus100 can include one or more rechargeable batteries (e.g., in the body110 and/or connected to plate 140) to power the electric vehicle. Insome embodiments, the body 110 includes or holds one or more modularrechargeable batteries. In some embodiments, the plate 140 is connectedto or secures one or more modular rechargeable batteries. When thebattery/modular battery is mechanically connected to the automatedsystem (on the vehicle), an electrical connection between the batteryand the vehicle can also be formed. The batteries can be part of aremovable tray that includes additional components for the vehicle. Thebatteries can be electrically connected to one another in the tray andthe tray can include one or more electrical outputs for electricallyconnecting the tray to the vehicle.

As an alternative to recharging the battery of the electric vehicle(e.g., in a rapid charging station or a traditional charging station),the battery (or modular batteries) can be replaced with a fully chargedbattery, or batteries, (e.g., the removable apparatus 100). The batteryreplacement can be completely automated using modular robots to removethe old batteries from the car and move the new batteries to approximatealignment with the automated system 10, as described above. An exampleof a robotic system to replace or recharge batteries (or batterymodules) in a vehicle is disclosed in U.S. Provisional Application No.62/180,686, entitled “Robot Assisted Modular Battery InterchangingSystem,” filed on Jun. 17, 2015, and its related applications, which arehereby incorporated by reference.

FIG. 2 illustrates a perspective view of a cross section of theautomated system 10 described above. In FIG. 2, additional details ofthe actuator gear 45 and bolt gear 50 are illustrated. The actuator gear45 is driven by actuating mechanism 40 (e.g., a motor). The actuatorgear 45 drives bolt gear 50, which in turn drives bolt 30 into nut 120.

Although the above system has been described with respect to a boltbeing driven by a robotic system into a nut disposed in a removableapparatus, it is recognized that the system can have the oppositeconfiguration. That is, a nut can be driven by the robotic system into abolt disposed in a removable apparatus.

FIG. 3 illustrates a side view of an exemplary automated system 300having an alternative configuration. The system 300 includes a roboticsystem 310 for driving a nut 320 into a bolt 330 disposed in removableapparatus 301. The nut 320 is disposed in a channel 385 defined in nutguide 380. Nut guide 380 is attached to a support plate 390, which canbe connected to a larger system (e.g., an electric vehicle) in someembodiments.

The robotic system 310 includes an actuating mechanism 350 (e.g., amotor) having an actuator gear 360 that mechanically communicates with abolt gear 370. The bolt gear 370 is mechanically coupled to nut 320 viashaft 375. The actuating mechanism 350 drives actuator gear 360, whichdrives bolt gear 370, which in turn drives shaft 375 and nut 320.

Removable apparatus 301 includes a body 305 having a channel 315 definedtherein to hold bolt 330, which is disposed on a spring 327. The channel315 can be square, hexagonal, or a similar shape (e.g., an angularshape) in a second cross section orthogonal to the plane defining theside view illustrated in FIG. 3. The shape and size of channel 315 areconfigured to prevent the bolt 330 from rotating when it is engaged bythe nut 320.

A plate 340 is disposed on the body 305. The plate 340 can be connectedto a larger system, such as a tray that holds multiple modularreplaceable electric batteries as described below. The plate 340includes a hole 345 disposed over the channel 315. The hole 345 has asmaller diameter than the channel 315 to retain the head 332 in thechannel 315. A tapered bolt guide 335 is disposed on the plate 340. Thetapered bolt guide 335 includes a hollow tapered region 337 to receivethe nut guide 380. The tapered portion 337 tapers from a wide diameterto a narrow diameter at base 339. The width of the base 339 isconfigured to secure the nut guide 380 so that the bolt 330 is alignedwith the nut 320. In some embodiments, the width of base 339 is about0.25″ to about 0.5″ larger than the width of nut guide 380.

In operation, the removable apparatus 301 is moved (e.g., by a secondrobotic system) below the automated system 300 for connection thereto.The removable apparatus 301 is positioned so that the bolt 330 is inapproximate alignment with the nut 320 (e.g., as illustrated in FIG. 3).The removable apparatus 301 and the automated system 300 are thenbrought closer to one another so that the bolt 330 and nut 320 are incontact with one another. In some embodiments, the removable apparatus301 is moved towards (e.g., raised, positioned from the side, etc.) theautomated system 300 (i.e., towards nut guide 380). In addition, or inthe alternative, the automated system 300 including nut guide 380 can bemoved towards (e.g., lowered, positioned from the side, etc.) theremovable apparatus 301.

FIG. 4 illustrates the automated system of FIG. 3 during a first stageof alignment. If the alignment of the nut guide 380 and bolt guide 335is offset, the nut guide 380 contacts an outwardly-tapered sidewall 339of the tapered guide 335 on removable apparatus 301 as the removableapparatus 301 is raised towards the automated system 300 (i.e., towardsnut guide 380).

FIG. 5 illustrates the automated system of FIG. 3 during a second stageof alignment. As illustrated in FIG. 5, the tapered sidewall 339 causesthe bolt guide 335 to align with the nut guide 380 as the bolt guide 335(and removable apparatus 301) is raised towards the nut guide 380. Nutguide 380 includes an outwardly-flared hollow portion 385 that extendsfrom nut 320 to the bottom face of nut guide 380. The hollow portion 385is configured to receive the tip 334 of the bolt 330 to align nut 320and bolt 330.

FIG. 6 illustrates the automated system of FIG. 3 during a third stageof alignment. As illustrated in FIG. 6, after the tip 334 of bolt 330passes through hollow portion 385 of nut guide 380, the nut 320 and bolt330 are aligned. The hollow portion 385 can also prevent that thecomplementary threads of nut 320 and bolt 330 are aligned and notcross-threaded. The hollow portion 385 can be about 0.2 inches to about0.4 inches in length, about 0.25 inches to about 0.35 inches in length,about 0.3 inches in length, or any length or range between any two ofthe foregoing values. As used herein, “about” means plus or minus 10% ofthe relevant value.

In some embodiments, the nut 320 and bolt 330 can include complementarychamfered portions proximal to the respective threads on nut 320 andbolt 330. For example, nut 330 can include a male chamfered portion andbolt 330 can include a female chamfered portion. Alternatively, nut 320can include a female chamfered portion and bolt 330 can include a malechamfered portion.

FIG. 7 illustrates the automated system of FIG. 3 in a fully-alignedstate. As illustrated, the nut 320 and bolt 330 are fully aligned andengaged.

FIG. 8 illustrates an automated system 800 having an alternativeconfiguration. As illustrated, the automated system 800 includes anactuating mechanism 850 (e.g., a motor) disposed above support plate890. Actuating mechanism 850 mechanically communicates and drives nut820 through bevel gear 855. Placing actuating mechanism 850 abovesupport plate 890 reduces the density of components disposed belowsupport plate 890, which can allow for a system having a higher densityof removable apparatus 801 (e.g., battery modules). In addition, theactuating mechanism 850 is protected by support plate 890 frominadvertent contact (e.g., by robots), which could damage actuatingmechanism 850.

Similar to previous figures, FIG. 8 illustrates a tapered bolt guide 835and a nut guide 880 including a flared portion, which are both used toalign nut 820 and bolt 830. FIGS. 9-12 illustrate the alignment andpositioning of bolt guide 835, nut guide 880, bolt 830, and nut 820,similar to the description above with respect to FIGS. 3-7.

FIG. 13 illustrates a perspective view of an automated system 1300including robotic system 1320 and removable apparatus 1301A in adisconnected state. The automated system 1300 includes a robotic system1320 that includes a plurality of actuators 1340 that are each connectedto respective bolts and bolt guides (and/or nuts and nut guides,depending on the embodiment), as described above. The removableapparatus 1301A comprises a tray 1310 that includes a plurality oftapered guides 1350 and respective channels for holding nuts and springs(and/or bolts and springs, depending on the embodiment), as describedabove. The tray 1310 can include a plurality of modular components(e.g., rechargeable batteries) or a single component. A plurality ofremovable apparatus 1301B, 1301C in a secured state is illustratedadjacent the disconnected removable apparatus 1301A for reference.

FIG. 14 illustrates a perspective view of the automated system 1300 ofFIG. 13 where each removable apparatus 1301A-1301C is in a securedstate.

It is appreciated that certain features of the invention, which are, forclarity, described in the context of separate embodiments, may also beprovided in combination in a single embodiment. Conversely, variousfeatures of the invention which are, for brevity, described in thecontext of a single embodiment, may also be provided separately or inany suitable sub-combination.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meanings as are commonly understood by one of ordinaryskill in the art to which this invention belongs. Although methodssimilar or equivalent to those described herein can be used in thepractice or testing of the present invention, suitable methods aredescribed herein. The present materials, methods, and examples areillustrative only and not intended to be limiting.

It will be appreciated by persons skilled in the art that the presentinvention is not limited to what has been particularly shown anddescribed hereinabove. Rather the scope of the present invention isdefined by the appended claims and includes both combinations andsub-combinations of the various features described hereinabove as wellas variations and modifications thereof, which would occur to personsskilled in the art upon reading the foregoing description.

What is claimed is:
 1. A method comprising: with a robot, raising aportable apparatus towards a stationary apparatus, the portableapparatus including an alignment guide that includes an alignment guidebody having opposing first and second faces, the alignment guide bodyhaving a cavity extending from the first face to the second face, thecavity defined by an internal tapered wall that tapers from a secondwidth at the second face to a first width at the first face, the secondwidth greater than the first width; inserting the stationary apparatusinto the cavity on the second face of the portable apparatus; aligning afirst threaded fastener at least partially disposed in a first housingof the stationary apparatus with a corresponding second threadedfastener at least partially disposed in a second housing of the portableapparatus, the alignment guide disposed on the second housing, thecorresponding second threaded fastener aligned with the cavity in thealignment guide; and rotating the first threaded fastener to engage andsecure the first threaded fastener with the corresponding secondthreaded fastener.
 2. The method of claim 1, further comprising stoppingthe rotating when a threshold torque level applied to the first threadedfastener is reached.
 3. The method of claim 1, further comprisingelectrically connecting a modular rechargeable battery unit comprised ofthe portable apparatus with a battery receptacle comprised of thestationary apparatus.
 4. The method of claim 3, further comprisingelectrically connecting the battery receptacle with a vehicle.
 5. Themethod of claim 1, further comprising sliding the first housing alongthe internal tapered wall to align the first threaded fastener with thecorresponding second threaded fastener.
 6. The method of claim 1,further comprising attaching the stationary apparatus to a supportplate.
 7. The method of claim 6, further comprising mechanicallycoupling a motor to the first threaded fastener, the motor secured tothe support plate.
 8. The method of claim 7, further comprising rotatingthe first threaded fastener with the motor.
 9. The method of claim 1,further comprising before raising the portable apparatus towards thestationary apparatus, placing the portable apparatus so that the secondthreaded fastener is at least partially aligned with the first threadedfastener.
 10. The method of claim 1, wherein a spring is disposedbetween the corresponding second threaded fastener and the secondhousing of the portable apparatus, and the method further comprisingapplying a force, with the spring, to press the corresponding secondthreaded fastener against the first threaded fastener when the firstthreaded fastener engages with the corresponding second threadedfastener.